Method of producing a spread multi-filament bundle and an apparatus used in the same

ABSTRACT

A method of producing a spread multi-filament bundle and an apparatus is used in which an arbitrary number of multi-filament bundles of higher strength are simultaneously spread with high speed and a high-quality. A spread multi-filament bundle or sheet with the component monofilaments thereof aligned in parallel widthwise and uniformly distributed in density is produced. The respective multi-filament bundles fed from a yarn supplier or a creel are subjected to fluctuation of the tensile force applied thereto alternatively between tension and relaxation and the respective bundles as subjected to such fluctuation are passed in succession through a fluid flowing spreader.

TECHNICAL FIELD

The invention relates to spreading a multi-filament bundle, in moredetails, pertaining to a method of mass-producing a high-quality spreadmulti-filament bundle and bundles sheet and an apparatus used thereinwherein a multi-filament bundle comprising the number of monofilamentsas desired in carriage is repeatedly put into contact with a fluid freefrom turbulent stream as many-times as necessary while beingcontinuously bent in a wavy form or if required, the bundle in carriageis repeatedly subjected to the fluctuation of the tensile force appliedthereto by locally and intermittently pressing the bundle in carriagecrosswise with regard to the moving course of the bundle or a linearlyback-and-forth friction is further provided widthwise with regard to thebundle in the process of being spread.

BACKGROUND ART

As well known, complex fiber reinforced materials comprising suchreinforced fibers as carbon fibers, glass fibers and aramid fibers andsuch matrix resins as epoxy resin are light in weight and superb inmechanical strength and anti-erosion so that they are widely utilizedfor such products for the general consumers as a fishing rod and a golfrod and structural parts of industrial machinery as well as for theconstruction of airplanes and space rockets. For manufacturing suchproducts and parts made from such complex fiber reinforced materials asmentioned above and constructing a fixed shape as required, suchmaterials are generally provided in such condition that a matrix resinis impregnated between the component monofilaments of a pre-impregnationsheet made from such reinforced fibers, the improvement on uniformdensity and thickness of which pre-impregnation sheet is sought afterdue to the recent expectation for further weight reduction of suchproducts and components of heavy construction.

The large-scale and inexpensive provision of such pre-impregnation sheetuniform in density and smaller in thickness as mentioned above enablesnot only thinner and lighter shaped products to be mass-produced, butalso pre-impregnation sheets whose monofilaments are uni-directionallyaligned to be laminated one over another with the direction of therespective sheets horizontally, vertically or diagonally displaced withregard to each other so as to obtain a multiplex pre-impregnation sheet.The production of such an article as being made from such multiplexpre-impregnation sheet as mentioned above could greatly improve rupturestrength of such article. Thus, it is highly expected among therespective industrial circles that a reasonable production technology ofa thinner spread multi-filaments sheet whose monofilaments are widthwisealigned in parallel and are distributed uniformly in density isestablished.

In this regard, reasonably producing a pre-impregnation sheet requiresthat a material cost of reinforced multi-filament bundles to be spreadbe reduced. Normally, the use of reinforced multi-filament bundle whosemonofilaments are less in number with such monofilamentsuni-directionally aligned facilitates the production of thepre-impregnation sheet smaller in thickness and whose monofilaments areuniformly distributed in density. However, the reinforced multi-filamentbundle whose monofilaments are less in number are expensive in cost sothat it is unavoidable that reinforced multi-filament bundle having anumber of monofilaments should be used. Thus, it necessitates a methodof spreading such reinforced multi-filament bundle having a number ofmonofilaments to form a thin reinforced multi-filament bundle spreadsheet so as to produce a pre-impregnation sheet whose thickness issmaller and whose monofilaments are uniformly distributed in density ina cost-effective manner compared to the prior art.

Conventionally, such methods are known as spreading respectivemonofilaments by subjecting multi-filament bundles to circular rods, andsplitting respective monofilaments widthwise by water stream orhigh-pressurized air stream and ultrasonically vibrating respectivemonofilaments bundles so as to split the same. As for some examples ofsuch method by the circular rods, it is disclosed in Japanese PatentApplication Laid-open-No. 56-43435 that the multi-filament bundles arepassed through and in engagement with a revolving roller that vibratesin the axial direction thereof so as to be spread, and it is disclosedin Japanese After-Grant Patent Application Laid-open No. 3-31823 thatthe multi-filaments are passed through and in engagement with aplurality of rollers that are disposed in displacement by 30 degrees to90 degrees to each other so as to be spread. Then, As for some examplesof such method by water stream or high-pressurized air stream, it isdisclosed in Japanese Patent Application Laid-open No. 52-151362 thatthe multi-filament bundles are subjected to high-pressurized fluid so asto be spread, and it is disclosed in Japanese Patent ApplicationLaid-open No. 57-77342 that the multi-filament bundles in carriage aresubjected to fluid flowing vertically with regard to the movingdirection of the former to apply dispersion force by such fluid to theformer so as to be spread. Further, as for an example of such ultrasonicmethod as mentioned above, it is disclosed in Japanese PatentApplication Laid-open No. 1-282362 that the multi-filament bundles areput into contact with a circular rod ultrasonically vibrating in theaxial direction thereof in a crosswise manner so as to be spread.

However, any one of the above prior arts is intended for spreadingmulti-filament bundles by applying physical force to the same so as toenforcedly move monofilaments comprising the same widthwise whilepulling the multi-filament bundles that tend to recover their convergedposition. In this reason, it causes the width of spread multi-filamentbundle to be made smaller than expected and the monofilaments to bedamaged, fluffed and cut after all. In change, in case of such circularrod as mentioned above, enhancing the feeding, speed of themulti-filament bundle causes the friction resistance between the rod andthe multi-filament bundle to be larger so as to further increase thenumber of monofilaments that are cut during operation while in case ofsuch water stream as mentioned above, a larger heating energy isrequired for drying up the water impregnated with the monofilaments.Accordingly, conventionally, an effective way is not yet to beestablished to continuously and stably spread the multi-filament bundlewith a higher feeding speed.

Under the above circumstances, the subject inventors have proposed inJapanese Patent No. 3049225 entitled ‘Method of producing a spreadfibers sheet and an apparatus used in the same’ and in Japanese PatentNo. 3064019 entitled ‘Method of producing a spread multi-filaments sheetand an apparatus used in the same’ wherein the multi-filament bundles ina flexibly bent condition are subjected to suction air flowing crosswisewith regard to the moving direction of the multi-filament bundles so asto spread the respective multi-filament bundles wider whosemonofilaments are uniformly distributed in density. These methods aresuccessful in spreading the respective multi-filament bundles widerwhose monofilaments are distributed in density by bending themulti-filament bundles so as to put the monofilaments comprising thesame into such condition to facilitate the widthwise movement thereofwithout enforcement or to put the monofilaments into such condition asfacilitating the same to be spread widthwise and by subjecting themonofilaments in such condition to suction air allowing air pass throughthe respective adjacent monofilaments.

However, such methods as proposed by the subject inventors and mentionedabove requires a spreading system in unit at least comprising a frontfeeder, a suction air cavity, a back feeder and a bending conditionmeasuring sensor. Thus, in order to distribute the monofilaments moreuniformly in density and spread the multi-filament bundle more widely,it is required that a series of such spreading systems be disposed insuccession so as to gradually proceed with the spreading operation ofthe same, which results in making the total system becoming muchlarger-in scale and more complicated in structure while spreadingoperation being simultaneously performed on a number of multi-filamentbundles disposed widthwise, it requires that a set of such spreadingsystems be arranged side by side, which results in the system as a wholebeing far larger in scale and by far more complicated in structure.

DISCLOSURE OF THE INVENTION

In view of the inconveniences encountered with the prior art forproducing a spread multi-filament bundle, the present invention is toprovide a method of efficiently producing a high-quality spreadmulti-filament bundle and a spread multi-filaments sheet whosemonofilaments are aligned widthwise in parallel and distributed in auniformed density and an apparatus used in the same method.

Further, the present invention is to provide a method of producing aspread multi-filament bundle that is wide enough to be used as areinforced matrix of FRTP (Fiber Reinforced Thermoplastics) and FRP(Fiber Reinforced Plastics) products and between whose adjacentmonofilaments a high-viscosity fusible thermoplastic resin is smoothlyand uniformly impregnated and an apparatus used in the same method.

Further, the present invention is to provide a method of economicallyproducing a spread multi-filament bundle larger in width enabling suchconverged monofilaments of higher strength as carbon fibers, glassfibers, ceramic fibers, aromatic polyamide fibers and so forth in aspace-saving and cost-saving manner and an apparatus used in the samemethod.

Furthermore, the present invention is to provide a method and anapparatus used in the same enabling an arbitrary number ofmulti-filament bundles of higher strength to be simultaneously spread ina high-speed operation and with ease.

The methodical and mechanical means adopted herein for solving the aboveissues are described below with reference to the accompanying drawings.

Firstly, the ‘method of producing a spread multi-filament bundle’according to the invention is characterized in that a multi-filamentbundle Tm fed from a yarn supplier 11 (bobbin, cone, cheese and soforth) is passed through in suspension a plurality of fluid flowingportions 31 a, 31 b, 31 c and so on respectively of the fluid flowingspreader 3 provided in series along the moving course of the bundle Tmto be subjected to fluidal resistance so as to bend towards thedirection to which a fluid flows and such fluid flows through aninterstice formed between the adjacent monofilaments of the bundle whosebonding of the adjacent monofilaments thereof being slackened due tosuch fluidal resistance so as to widen such interstice between theadjacent monofilaments thereof, thereby, further promoting spreadingoperation oh the bundle, wherein the bundle Tm to be subjected to suchspreading operation is passed through in succession the fluid flowingportion 31 a located at an upstream side and the respective fluidflowing portions 31 b and 31 c and so forth located at a downstream sideso as to gradually enlarge contact area between the bundle Tm and suchfluid, thereby, widely spreading the bundle Tm in a progressive manner.

Then, the ‘method of producing a spread multi-filament bundle’ accordingto the invention is characterized in that the tensile force applied to amulti-filament bundle in carriage is fluctuated alternatively andrepeatedly between tension and relaxation by locally and intermittentlypressing a multi-filament bundle Tm fed from a yarn supplier 11widthwise with regard to the bundle Tm and the bundle Tm under suchfluctuation is passed through in suspension a plurality of fluid flowingportions 31 a, 31 b, 31 c and so-on respectively of the fluid flowingspreader 3 provided in series along the moving course of the bundle Tmto be subjected to fluidal resistance so as to bend towards thedirection to which a fluid flows, and such fluid flows through aninterstice formed between the adjacent monofilaments of the bundle whosebonding is slackened due to such fluidal resistance so as to widen suchinterstice between the adjacent monofilaments thereof, thereby, furtherpromoting spreading operation on the bundle, wherein the bundle Tm to besubjected to such spreading operation is passed through in successionthe fluid flowing portion 31 a located at an upstream side and therespective fluid flowing portions 31 b and 31 c and so forth located ata downstream side so as to gradually enlarge contact area between thebundle Tm and such fluid, thereby, widely spreading the bundle Tm in aprogressive manner. Commenting further, spreading operation is moreeffectively performed by feeding the multi-filament bundle Tm unwoundfrom the yarn supplier 11 with the restrain of being drawn back andchanging the tensile force applied to the bundle Tm in carriagealternatively and repeatedly between tension and relaxation by locallyand intermittently pressing the bundle Tm in carriage widthwise withregard to the bundle Tm, which operation is by far more effectivelyperformed by providing linearly back-and-forth friction widthwise withregard to the spread bundle Ts discharged from the farthest fluidflowing portion 31 c.

Then, the ‘method of producing a spread multi-filament bundle’ accordingto the invention is characterized in that a number of bundles Tm•Tm . .. that are unwound from the respective yarn suppliers 11•11 . . . of acreel 1 are fed with aligned in parallel in the same plane while therespective bundles Tm•Tm . . . in feed are passed through in suspensiona plurality of fluid flowing portions 31 a, 31 b, 31 c and so onrespectively of the fluid flowing-spreader 3 provided in series alongthe moving course of the respective bundles Tm to be subjected tofluidal resistance so as to bend towards the direction to which a fluidflows, and such fluid flows through an interstice formed between theadjacent monofilaments of the respective bundles-whose bonding isslackened due to such fluidal resistance so as to widen such intersticebetween the adjacent monofilaments thereof, thereby, further promotingspreading operation on the respective bundles so as to be formed intothe respective spread bundles Ts, and the tensile force applied to therespective spread bundles Ts in carriage is fluctuated alternatively andreciprocally between tension and relaxation by locally andintermittently pressing a group of the respective spread bundles Tsmoving in the same direction widthwise with regard to the respectivespread bundles Ts so as to further promote spreading operation by therespective fluid flowing portions 31 a, 31 b, 31 c and so forth.

Further, the ‘method of producing a spread multi-filament bundle’according to the invention is characterized in that a number of bundlesTm•Tm . . . that are unwound from the respective yarn suppliers 11•11 .. . of a creel 1 are fed with aligned in parallel in the same planewhile the respective bundles Tm•Tm . . . in feed are passed through insuspension a plurality of fluid flowing portions 31 a, 31 b, 31 c and soon respectively of the fluid flowing spreader 3 provided in series alongthe moving course of the respective bundles Tm to be subjected tofluidal resistance so as to bend towards the direction to which a fluidflows, and such fluid flows through an interstice formed between theadjacent monofilaments of the respective bundles whose bonding isslackened due to such fluidal resistance so as to widen such intersticebetween the adjacent monofilaments thereof, thereby, further promotingspreading operation on the respective bundles so as to be formed intothe respective spread bundles Ts, and linearly back-and-forth frictionis provided widthwise with regard to a group of the respective spreadbundles Ts moving in the same plane to tangentially align the fringeside monofilaments of any adjacent spread bundles Ts and Ts so as to beformed into a spread multi-filament bundles sheet Tw whose monofilamentsas a whole are uniformly distributed in density. Commenting further,spreading operation is more effectively performed by fluctuating thetensile force applied to the respective spread bundles Ts in carriagealternatively between tension and relaxation by locally andintermittently pressing a group of the respective spread bundles Tswidthwise with regard to the respective spread bundles prior to beingsubjected to the back-and-forth friction widthwise with regard to therespective spread bundles.

Further, the ‘method of producing a spread multi-filament bundle’according to the invention is characterized in the provision of afloating control bridge 35 in the respective fluid flowing portions 31a, 31 b, 31 c and so forth that serves to secure a certain bendingdegree of the respective bundles in passage.

Then, the ‘apparatus for spreading a multi-filament bundle used in theabove method’ according to the invention that is adopted as a mechanicalmeans for solving the above issues is characterized in comprising a yarnsupplier 11 such as bobbin, cone, cheese and so forth) or a creelprovided with a number of such yarn suppliers 11 around which amulti-filament bundle Tm is wound; a multi-filament bundle feeder 2 tounwind and feed the bundle Tm or the respective bundles Tm•Tm . . .under a certain tensile force from the yarn supplier 11 or the creel 1with the drawing-back of the bundle Tm or the respective bundles Tm•Tm .. . in check; a fluid flowing system 3 comprising fluid flowing portions31 a, 31 b, 31 c and so forth that are disposed in succession along themoving course of the bundle Tm or the respective bundles Tm•Tm . . . infeed to put a fluid into contact crosswise with regard to and pass thefluid through the bundle Tm or the respective bundles Tm•Tm . . . inpassage with the latter supported thereon in suspension and to bend thebundle Tm or the respective bundles Tm•Tm . . . towards the direction towhich such fluid flows so as to spread the same; a tensile forcevariable system 4 (refer to FIG. 3) to change the tensile force appliedto the bundle or the respective bundles in carriage alternativelybetween tension and relaxation.

Further, the ‘apparatus for spreading a multi-filament bundle used inthe above method’ according to the invention that is adopted as amechanical means for solving the above issues is characterized incomprising a yarn supplier 11 or a creel provided with a number of suchyarn suppliers 11 around which a multi-filament bundle Tm is wound; abundle feeder 2 to unwind and feed the bundle Tm or the respectivebundles Tm•Tm . . . under a certain tensile force from the yarn supplier11 or the creel 1 with the drawing-back of the bundle Tm or therespective bundles Tm•Tm . . . in check; a fluid flowing system 3comprising fluid flowing portions 31 a, 31 b, 31 c and so forth that aredisposed in succession along the moving course of the bundle Tm or therespective bundles Tm•Tm . . . in feed to put a fluid into contactcrosswise with regard to and pass the fluid through the bundle Tm or therespective bundles Tm•Tm . . . with the latter supported thereon and tobend the bundle Tm or the respective bundles Tm•Tm . . . towards thedirection to which such fluid flows so as to spread the same; a tensileforce variable system 4 to change the tensile force applied to thebundle or the respective bundles in feed alternatively between tensionand relaxation and a widthwise back-and-forth friction system 6 to moveback and forth widthwise with regard to the bundle Tm or the respectivebundles Tm in the process of being spread in abutment with therespective monofilaments comprising the bundle Tm or the respectivebundles Tm to apply friction to the respective monofilaments thereof.

Now, several supplemental follow-ups of the present invention aredescribed below in terms of the technical matters of the presentinvention.

-   (1) although the multi-filament bundle that the present invention    encompasses is mainly of such conventionally known monofilaments of    higher strength as carbon fiber, glass fiber, ceramic fiber,    polyoxymethylene fiber, polyamide fiber and so forth that are used    as reinforced matrix of FRTP (Fiber Reinforced Thermoplastics) and    FRP (Fiber Reinforced Plastics) products being converged into a    multi-filament bundle, the present invention also covers a    multi-filament bundle in which a number of metallic monofilaments or    conventionally known synthetic monofilaments are converged into a    multi-filament bundle and could encompass every types of    multi-filament bundles as necessary other than those mentioned above    on a case-on-case basis.-   (2) then, as for the type of fluid in use for acting on a    multi-filament bundle so as to spread the bundle in contact    therewith, it includes a kinetic energy generated by gas flow such    as air and vapor, that generated by liquid flow such as water and    others or that generated by liquid-gas two-phase flow.-   (3) as for fluid flowing portions 31 a, 31 b, 31 c, 31 d and so on    comprising a fluid flowing system 3, the fluid velocity of the    respective portions may be equal or different. For example, there    may be difference in the fluid velocity among the respective flowing    portions from higher velocity to smaller velocity or vice versus.    According to the progress of a multi-filament bundle being spread,    the most efficient fluid velocity thereof may be selected.-   (4) to note, in the present invention, the tensile force applied to    a multi-filament bundle Tm and the fluid velocity shall be fixed in    considerations of the physical property and the moving speed of the    multi-filament bundle in use, since the respective monofilaments    comprising the bundle are supposed to move widthwise to be spread    and to flexibly bend, when the multi-filament bundle Tm passes in    suspension through the fluid flowing portions 31 a, 31 b, 31 c, 31 d    and so on disposed in series along the moving course of the bundle    Tm. Too strong tensile force being applied to the respective bundles    and the flowing velocity of a fluid being too slow causes the    respective bundles to pass over the respective fluid flowing    portions without bending towards the direction to which the fluid    flows, which results in failing to perform spreading operation    smoothly.    Effect

As described up to here, the invention makes most of such fluid dynamismas the respective multi-filament bundles unwound and fed from the creelat the same speed with aligned in parallel in the same plan beingsubjected to fluidal resistance while passing over in suspension aplurality of fluid flowing portions disposed in succession along themoving course of the respective bundles comprising a fluid flowingspreader so as to be bent towards the fluid flowing direction, throughany adjacent monofilaments of which bundles respectively as subjected tosuch fluidal resistance and slackened the fluid in use flows, so that anideal widely spread multi-filaments sheet with the side fringemonofilaments of any adjacent bundles tangentially aligned in paralleland uniform in density is efficiently mass-produced.

The invention adopts such mechanism as either one multi-filament bundleor a plurality of multi-filament bundles fed from a supplier or a creelwith the restraint of being drawn back being subjected to the change ofthe tensile force applied thereto between tension and relaxation and thebundle or the respective bundles being subjected to fluidal resistancewhile passing over a plurality of fluid flowing portions disposed inline along the moving course thereof so as to be bent towards the fluidflowing direction, through any adjacent monofilaments of which bundle orbundles respectively subjected to such fluidal resistance and slackenedthe fluid flows. Thus, spreading operation is performed with highefficiency both for producing spread multi-filament bundles and forproducing an ideal widely spread multi-filaments sheet with the fringeside monofilaments of any adjacent bundles tangentially aligned inparallel and uniform in density.

The adoption of the means to provide back-and-forth linearly frictionwidthwise with regard to the respective multi-filament bundles in theprocess of being spread and subjected to the change of the tensile forcebetween tension and relaxation permits spread multi-filament bundles ora widely spread multi-filaments sheet to be produced with less damage onthe component monofilaments thereof and with the component monofilamentsthereof distributed uniformly as a whole. Thus, a high-quality spreadmulti-filaments sheet, which is wide enough to use as a reinforcedmaterial for an article made from FRP and FRTP and is good at resinpermeability enabling a fusible thermoplastic resin of high viscosity tobe uniformly and smoothly impregnated between the componentmonofilaments thereof, is provided in an inexpensive way.

By use of such an extremely streamlined apparatus as essentiallyconsisting of a creel provided with a yarn supplier or a plurality ofyarn suppliers, a multi-filament bundle supplier, a fluid flowingspreader provided with a plurality of fluid flowing portions and atensile force variable system to change the tensile force applied to therespective multi-filament bundles alternatively between tension andrelaxation, a multi-filament bundle comprising carbon fibers, ceramicfibers, polyoxymethylene fibers, aromatic polyamide resin and so forthis processed into a high-quality widely spread multi-filaments in aspace-saving and cost-saving manner with high efficiency.

BRIEF DECSRIPTION OF THE DRAWINGS

FIG. 1 is an explanatory side view of an apparatus example 1 used in themethod of producing a spread multi-filament bundle according to thefirst-embodiment hereof;

FIG. 2 is an explanatory plan view of the apparatus example 1 shown inFIG. 1;

FIGS. 3( a) and (b) are illustrations to show the effect on themulti-filament bundle passing through the fluid flowing portionsaccording to the operation of the tensile force variable system;

FIG. 4 is an explanatory side view of an apparatus example 2 used in themethod of producing a spread multi-filament bundle according to thesecond embodiment hereof;

FIG. 5 is an explanatory plan view of the apparatus example 2 shown inFIG. 4;

FIG. 6 is an explanatory plan view of the apparatus example 2 used inthe method of producing a spread multi-filament bundle according to thethird embodiment hereof;

FIG. 7 is an explanatory side view of an apparatus example 3 used in themethod of producing a multi-filament bundle according to the thirdembodiment hereof;

FIG. 8 is an explanatory plan view of the apparatus example 3 shown inFIG. 7;

FIG. 9 is an explanatory side view of an apparatus example 4 used in themethod of producing a multi-filament bundle according to the thirdembodiment hereof;

FIG. 10 is an explanatory plane view of the apparatus example 4 shown inFIG. 9;

FIG. 11 is an explanatory side view of an apparatus example 5 used inthe method of producing a multi-filament bundle according to the thirdembodiment hereof;

FIG. 12 is an explanatory side view of an apparatus example 6 used inthe method of producing a spread multi-filament bundle according to thethird embodiment hereof;

FIG. 13 is an explanatory side view of an apparatus example 7 used inthe method of producing a spread multi-filament bundle according to thefourth embodiment hereof;

FIG. 14 comprises illustrations showing the state where the spreadmulti-filament bundles are overlapped one over another and proceed to beformed into a spread multi-filaments sheet according to the fourthembodiment hereof;

FIG. 15 comprises illustrations showing the state where the spreadmulti-filaments sheets are overlapped one over another so as to beformed into a commingled spread multi-filaments sheet;

FIG. 16 is an explanatory side view of an apparatus example 8 used inthe method of producing a spread multi-filament bundle according to thefifth embodiment hereof;

FIG. 17 is an explanatory plan view of the apparatus example 8 shown inFIG. 16;

FIG. 18 is an explanatory side view of an apparatus example 9 used inthe method of producing a spread multi-filament bundle according to thesixth embodiment hereof;

FIG. 19 is an explanatory plan view of the apparatus example 9 shown inFIG. 18;

FIG. 20 is an explanatory side view of another apparatus example 10 usedin the method of producing a spread multi-filament bundle according tothe sixth embodiment hereof;

FIG. 21 is an explanatory plan view of the apparatus example 10 shown inFIG. 20;

FIG. 22 is an enlarged view of the internal structure of the fluidflowing portion of the apparatus example 10;

FIG. 23 is a sectional view taken along A-A of FIG. 22;

FIG. 24 is an explanatory side view of another apparatus example 11 usedin the method of producing a spread multi-filament bundle according tothe sixth embodiment hereof;

FIG. 25 is an explanatory side view of another apparatus example 12 usedin the method of producing a spread multi-filament bundle according tothe sixth embodiment hereof;

FIG. 26 is an enlarged plan view showing the linkage relation amongguide rollers, a crank motor, a crank arm and a linkage mechanismcomprising a widthwise back-and-forth friction system of the apparatusexample 12 shown in FIG. 25;

FIG. 27 is a structural view showing the mechanism in which therotary-motion of the crank motor is converted into a widthwiseback-and-forth movement transmitted to guide rollers;

FIG. 28 is an explanatory side view of another apparatus example 13 usedin the method of producing a spread multi-filament bundle according tothe sixth embodiment hereof;

FIG. 29 is an explanatory side view of another apparatus example 14 usedin the method of producing a spread multi-filament bundle according tothe sixth embodiment hereof;

FIG. 30 is an explanatory side view of another apparatus example 15 usedin the method of producing a spread multi-filament bundle according tothe sixth embodiment hereof;

FIG. 31 is an explanatory side view of another apparatus example 16 usedin the method of producing a spread multi-filament bundle according tothe sixth embodiment hereof;

FIG. 32 is an explanatory side view of an apparatus example 17 used inthe method of producing a spread multi-filament bundle according to theseventh embodiment hereof;

FIG. 33 is an explanatory side view of another apparatus example 18 usedin the method of producing a spread multi-filament bundle according tothe seventh embodiment hereof; and

FIG. 34 shows a modified example of the third embodiment hereof in whicha resin sheet is fused onto the upper and bottom surfaces respectivelyof the spread multi-filaments sheet so as to produce a pre-imaginationsheet.

BEST MODE FOR CARRYING OUT THE INVENTION

Hereafter, the preferred embodiments of the invention are described inmore details with reference to the accompanying drawings.

First Embodiment

In the present embodiment, the mechanism by which one multi-filamentbundle is spread by means of an apparatus example 1 as shown in FIGS. 1through 3 is explained as follows.

Apparatus Example 1

Reference numeral 11 in FIGS. 1 and 2 indicates a yarn supplier ofbobbin type around which a long multi-filament bundle Tm is wound, whichsupplier is supported into a bobbin shaft 12 a engaged to a power shaftof a yarn supply motor 12 and from which supplier the bundle Tm isunwound by the rotation of the motor 12. The multi-filament bundle thatthe present embodiment encompasses includes such reinforced fibersbundles whose component monofilaments are of higher strength as a carbonfibers bundle, a glass fibers bundle, an aramid fibers bundle and aceramic fibers bundle and such thermoplastic resin fibers bundles asmonofilaments made from polyethylene, polypropylene, nylon 6, nylon 66,nylon 12, polyethylene terephtalate, polyphenylene sulfide, polyetherether ketone being bundled. It should be noted that either anon-stranded multi-filament bundle or a preliminarily untwistedmulti-filament bundle is put to use for the purpose of saving productioncost, since a stranded multi-filament bundle can not be spreadcontinuously without untwisting the same.

Then, reference numeral 2 in the drawings indicates a multi-filamentbundle feeder, which feeder comprises a rotatable guide roller 21 tosupport a multi-filament bundle Tm unwound from the yarn supplier 11 ina fixed position; a pair of anterior and posterior revolving supportrollers 22 and 22 to support the bundle Tm at a downstream side from theguide roller 21; a tension stabilizing roller 24 a rotatably disposedbetween the support roller 22 at a upstream side and the guide roller 21to abut the bundle Tm in passage and to ascend and descend according tochange of tensile force applied to the bundle Tm so as to keep a tensionof the bundle Tm constant; an upper limit position sensor 25 a to detectthe upper limit position of the tension stabilizing roller 24 a and alower limit position sensor 25 b to detect the lower limit positionthereof; a nip roller 23 a to press against the support roller 22 at adownstream side and to roll with the bundle Tm sandwiched between itselfand the roller 22; and a uni-directionally rotatable clutch 23 b torotate the nip roller 23 a only to a feeding direction of the bundle Tmso as to prevent the bundle Tm from being drawn back to a reversedirection to the feeding course thereof.

The stabilization of the tensile force applied to the bundle Tm that isdrawn out from the yarn supplier 11 of the apparatus example 1 isrealized as follows. Namely, the tension stabilizing roller 24 a of themulti-filament bundle feeder moves upwards when the tension of thebundle Tm in passage is increased while moving downwards when the sameis decreased. Then, when the tension stabilizing roller 24 a reaches atthe upper limit position thereof, the upper limit position sensor 25 adetects such position and a signal to that effect is input to the yarnsupply motor 12 to increase the revolving speed of the yarn supplier 11so as to increase feeding the bundle Tm while to descend the tensionstabilizing roller 24 a. On the other hand, when the tension stabilizingroller 24 a reaches at the lower limit position thereof, the lower limitposition sensor 25 b detects such position and a signal to that effectis input to the yarn supply motor 12 to decrease the revolving speed ofthe yarn supplier 11 so as to decrease feeding the bundle Tm. In thisway, the tensile force applied to the bundle Tm by use of the apparatusexample 1 is always kept constant.

The bundle Tm provided with a certain initial tension as mentioned aboveproceeds to run between the support roller 22 and the nip roller 23 a.In this regard, the nip roller 23 a is provided with a uni-directionallyrotatable clutch 23 b so that the nip roller 23 a does not rotate to areverse direction to the feeding direction of the bundle and there is noeffect on the upstream side from the nip roller 23 a even if the bundleis subjected to reciprocal tension and relaxation by a tensile forcevariable system disposed at a downstream side as mentioned below,thereby, the bundle Tm being unwound along the feeding course thereofwith a constant tension.

Then, reference numeral 3 in the drawings indicates a fluid flowingspreader of cavity tube type. A suction cavity tube, the aperture ofwhich tube acts as a fluid flowing portion 31 a, is adopted herein forthe fluid flowing spreader. This fluid flowing portion 31 a is disposedin the same elevation level as the feeding course of the bundle Tm, onan entrance side and an exit side respectively of which portion 31 a aguide roller 32 is disposed to keep the bundle Tm in passage at acertain elevation level. The fluid flowing portion 31 a acting as asuction cavity tube is provided with a suction air pump 34, and theoperation of the suction air pump 34 with a flow rate adjustment valve33 regulated as necessary causes suction air stream with a flow rate asrequired inside the fluid flowing portion 31 a.

Then, reference numeral 4 in the drawings indicates a tensile forcevariable system, which system is disposed between a pair of anterior andposterior support rollers 41 and 41 horizontally disposed with aninterval therebetween at a downstream side from the fluid flowingspreader 3. This tensile force variable system 4 of the apparatusexample example 1 comprises an elevating rod 42 provided with a pressroller 42 a at a lower end portion thereof; an extensile and contractilecrank arm 43 engaged to the elevating rod 42; and a crank motor 44 whosepower shaft is provided with a rotor 43 a in engagement to the crank arm43. According to the ascend and descend of the elevating rod 42 causedthrough the crank arm 43 by driving the crank motor 44 so as to rotatethe rotor 43 a, the press roller 42 a repeats to perform a push-down,and detachment operation with regard to the bundle Tm in the process ofbeing spread so that the tensile force applied to the bundle Tm changesalternatively between tension and relaxation. This tensile forcevariable system 4 is disposed between a pair of support rollers 41 and41 that support the bundle in the process of being spread at a certainelevation level. To note, the change of the revolving speed of the crankmotor 44 allows the reciprocal cycle of tension and relaxation performedon the bundle Tm to be regulated.

While the bundle Tm is in the middle of passing through the fluidflowing portion 31 a in suspension after having passed a section wherethe bundle Tm is sandwiched between the support roller 22 and the niproller 23 a, the bundle Tm is reciprocally subjected to the suddenchange of the tensile force applied thereto between tension andrelaxation by the press roller 42 a of the tensile force variable system4 provided at a downstream side, which change affects the section wherethe bundle Tm is sandwiched between the support roller 22 and the niproller 23 a. Thus, upon the bundle Tm affected by such reciprocaltension and relaxation as mentioned above being subjected to suction airstream, when the tensile force applied to the bundle Tm changes fromtension to relaxation as shown by the arrow (a) to (b) in FIG. 3, thebundle Tm bends towards the direction to which the air stream flows sothat the length of the respective monofilaments existing inside thefluid flowing portion 31 a momentarily becomes larger so as tofacilitate the bundle being spread widthwise. That is to say, therelaxation of the bundle slackens the tension between adjacentmonofilaments so as to increase the volume of air stream to flow throughsuch adjacent monofilaments, which results in the spreading operationbeing intensified. On the contrary, when the tensile force applied tothe bundle changes from relaxation to tension as shown by the arrow (b)to (a) in FIG. 3, the degree to which the bundle Tm bends inside thefluid flowing portion 31 a reduces, and the respective componentmonofilaments are aligned in a straight manner as if they are combed bythe suction air stream with the spread bundle maintained as it is.

The spread multi-filament bundle Ts in this way is taken up by a take-upmechanism 5, which mechanism comprises a pair of take-up rollers 51 and51 and a take-up motor 52. To follow up the above explanation, themoving speed of the bundle is determined by the revolving speed of themotor 52, which moving speed is adjustable by controlling the motor 52with a speed setter not shown in the drawings. Further, a wind-up beamnot shown in the drawings is disposed at a downstream side from thetake-up mechanism 5 to wind up the spread multi-filament bundle Ts, anda pre-impregnation device not shown in the drawings may be provided inseries to perform an impregnation of the variety of resins on the spreadmulti-filament bundle Ts, if required.

Second Embodiment

In the present embodiment, the mechanism by which a number of spreadmulti-filament bundles are produced by use of an apparatus example 2 asshown in FIGS. 4 and 5.

Apparatus Example 2

Reference numeral 1 in the drawings indicates a creel in which a numberof yarn suppliers 11 of bobbin type (five yarn suppliers beingillustrated herein) around which a long multi-filament bundle Tm iswound in a number of layers are disposed in multi-stages. In the sameway as the apparatus example 1, a yarn supply motor 12 is provided withthe respective yarn suppliers 11 of the apparatus example 2, therotation of which motor allows the bundle Tm to be unwound from therespective suppliers 11.

A number of the multi-filament bundles Tm are drawn out from the yarnsuppliers 11•11 . . . of the creel 1, the respective bundles Tm•Tm . . .as drawn out being taken up by a multi-filament bundle feeder 2 disposedcorresponding to each of those bundles. The basic structure of theportions of the respective multi-filament bundle feeders 2 of theapparatus example 2 corresponding to the respective yarn suppliers 11 isthe same as that of the apparatus example 1, which bundle feedercomprises a rotatable guide roller 21 to support a multi-filament bundleTm unwound and fed from the yarn supplier 11 in a fixed position; a pairof anterior and posterior support rollers 22 and 22 rotatably disposedat a downstream side from the guide roller 21 to support themulti-filament bundles Tm; a tension stabilizing roller 24 a rotatablydisposed between the support roller 22 at an upstream side and the guideroller 21 to abut the multi-filament bundle Tm in passage and to ascendand descend according to change of tensile force applied to the bundleTm so as to keep the tension of the bundle Tm constant; a upper limitposition sensor 25 a to detect the upper limit position of the tensionstabilizing roller 24 a and a lower limit position sensor 25 b to detectthe lower limit position thereof; a nip roller 23 a to press against thesupport roller 22 at a downstream side and to roll with the bundle Tmsandwiched between itself and the support roller 22 at a downstreamside; and a uni-directionally revolving clutch 23 b to rotate the niproller only to a feeding direction of the bundle Tm so as to prevent thebundle from being drawn back. To note, a pair of upper and loweralignment guide rollers 26 and 26 are provided with the apparatusexample 2 in addition to the above structural elements, because therespective multi-filament bundles Tm as unwound need to be aligned inparallel in the same elevation level so as to put a group of therespective bundles in order, in view of the fact that the yarn suppliers11•11 . . . are laid in multi-stages in case of the apparatus example 2.Those guide rollers 26 and 26 are intended for sandwiching therebetweena number of multi-filament bundles Tm unwound from the yarn suppliers 11in multi-stages in the same elevation level so as to control therespective bundles such that they are arranged into an orderly alignedgroup of the bundles Tm•Tm . . . in parallel with each other and in thesame elevation level. The provision of those guide rollers 26 and 26prevents the fluctuation of the tension to which the respective bundlesare subjected at a tensile force variable system as described below fromaffecting an upstream side from those rollers.

When the tension applied to any one of the bundles Tm•Tm . . . taken upby the multi-filament bundle feeder 2 and passing the tensionstabilizing roller 24 a increases, the tension stabilizing roller 24 agoes upwards while going downwards when the same decrease in the sameway as the apparatus example 1. When the tension stabilizing roller 24 areaches at an upper limit position thereof, the upper limit positionsensor 25 a detects such position and a signal to that effect is inputto the yarn supply motor 12 to increase the revolution of the yarnsupplier so as to augment the amount by which the bundle T is unwound.On the contrary, when the tension stabilizing roller 24 a reaches at alower limit position thereof, the lower limit position sensor 25 bdetects such position and a signal to that effect is input to the yarnsupply motor 12 to decrease the revolution of the yarn supplier 11 so asto reduce the amount by which the bundle Tm is unwound. Then, therespective bundles Tm•Tm . . . are guided into the alignment guiderollers 26 and 26 with the tension thereof kept constant by theself-control action of the multi-filament bundle feeder 2 so as to bealigned in parallel with each other and in the same elevation level.

Then, the respective multi-filament bundles Tm•Tm . . . that have passedthrough the alignment guide rollers 26 and 26 move from a fluid flowingspreader 3 via a tensile force variable system 4 to a take-up roller 5.The arrangement of the multi-filament bundle feeder 2, the fluid flowingspreader 3, the tensile force variable system 4 and the take-up system 5respectively comprising the apparatus example 2 is substantially thesame as that of the apparatus example 1, but the apparatus example 2 isprovided with some design modifications in view of a number of bundlesTm (five bundles herein) being subjected to spreading operation. Thus,such modifications are supplemented as follows. To note, the explanationof the multi-filament bundle feeder 2 is omitted to avoid-redundancy.

Firstly, the fluid flowing spreader 3 of the apparatus example 2 adoptsthe same cavity tube type as the apparatus example 1, but the differencebetween them lies in as follows. That is to say, the fluid flowingspreader 3 of the apparatus example 2 is provided with three fluidflowing portions 31 a, 31 b and 31 c, the opening width of which isenlarged, in this order from a downstream side to an upstream side, inview of the necessity that suction air stream is acted on the respectivebundles Tm•Tm . . . as a whole. The opening of the respective fluidflowing portions 31 a, 31 b and 31 c is disposed in the same elevationlevel as the feeding course of the respective bundles, on an entranceside and an exit side respectively of which opening a guide roller 32 isprovided to support the respective bundles Tm in passage at a certainelevation level. Suction air stream is generated inside the respectivefluid flowing portions 31 a, 31 b and 31 c by driving a suction pump 34,which pump is provided with a flow rate adjustment valve, 33 so that theflow velocity of the suction air stream inside the respective fluidflowing portions is controlled by the flow rate adjustment valve 33regulated as necessary.

Then, the tensile force variable system 4 of the apparatus example 2 isthe same as that of the apparatus example 1 in that it comprises anelevating rod 42 provided with a press roller 42 a at a lower endportion thereof; a contractile and extensile crank arm 43 engaged to theelevating rod 42; and a crank motor 44 whose power shaft is providedwith a rotor 43 a in engagement to the crank arm 43 and that the system4 is provided between the upstream and downstream support rollers 41 and41 with an interval. However, the elevating rod 42 of the tensile forcevariable system 4 hereof is provided with a press roller 42 a at a lowerend portion thereof wide enough to press against the respective bundlesTm•Tm . . . moving in parallel with each other.

Upon the rotation of the rotor 43 a by driving the crank motor 44, theelevating rod 42 moves up and down through the crank arm 43 so that thepress roller 42 a performs a push-down and detachment operation withregard to the respective bundles Tm•Tm . . . in the process of beingspread so as to change the tensile force applied to the respectivebundles alternatively between tension and relaxation at a certaintiming, the fluctuation of which tensile force applied thereto affectsup to the alignment guide rollers 26 and 26 disposed at an upstream sideand is set off there. The respective bundles Tm•Tm . . . passing throughthe fluid flowing portions 31 a, 31 b and 31 c are subjected to thechange of the tensile force applied thereto between tension andrelaxation by the action of the press roller 42 a. Upon the respectivebundles under such fluctuation being subjected to suction air stream,the tension between adjacent monofilaments of the respective bundles isrelaxed to increase the volume by which the suction air stream flowsthrough such adjacent monofilaments so as to intensify the spreadingoperation thereon when the tensile force applied to the respectivebundles is in a mode of relaxation. On the other hand, when the tensileforce applied thereto changes from relaxation to tension, the respectivebundles are aligned in a straight manner as if they are combed by thesuction air stream with the spread bundles maintained as they are. Thosefavorable actions are already noted in the apparatus example 1.

Then, the respective spread multi-filament bundles Ts•Ts . . . whosewidth is enlarged at the fluid flowing-spreader 3 and that are subjectedto the change of the tensile force applied thereto at a certain timingbetween tension and relaxation are taken up by the take-up system 5. Thesystem 5 of the apparatus example 2 comprises a pair of upper and lowertake-up rollers 51 and 51 and a motor 52 to drive those rollers.However, those rollers wide enough to simultaneously wind up a number ofthe spread multi-filament bundles Ts are adopted herein.

Third Embodiment

In the present embodiment, the same apparatus as the apparatus example 2is used for producing a spread multi-filaments sheet. The process inwhich a number of multi-filament bundles Tm•Tm . . . are spreadwidthwise so as to be formed into one piece of a spread multi-filamentbundles sheet Tw is shown in FIG. 6.

The explanation on the apparatus used for producing a spreadmulti-filaments sheet in the present embodiment is omitted, as thestructural arrangement thereof is the same as that of the apparatusexample 2. In this embodiment too, spreading operation is performed on anumber of multi-filament bundles Tm•Tm . . . in the same way as thesecond embodiment. The difference between the present embodiment and thesecond one lies in as follows.

Namely, the present embodiment is methodically characterized inpredetermining a maximum width to be spread for the respectivemulti-filament bundles Tm and feeding the respective bundles Tm from therespective yarn suppliers 11 with each of them disposed side by sidewith an interval corresponding to such maximum width and moving them tothe tensile force variable system 4 via the multi-filaments feeder 2 andthe fluid flowing spreader 3, in which the respective bundles aresynergistically subjected to suction air stream at the fluid flowingspreader 3 and to the change of the tensile force applied theretobetween tension and relaxation at the tensile force variable system 4 soas to be gradually spread, and in integrating the spread bundles into aspread multi-filament bundles sheet Tw with the fringe sidemonofilaments of any adjacent spread bundles tangentially lined side byside.

The method of producing a spread multi-filament bundles sheet accordingto the present embodiment may be carried out by use of an apparatusexample 3 as shown in FIGS. 7 and 8.

Apparatus Example 3

The difference between the apparatus example 2 and the apparatusaccording to the present embodiment lies in that the latter is providedwith a widthwise back-and-forth friction system 6 between the tensileforce variable system 4 and the take-up system 5 to linearly provide aback-and-forth friction widthwise with regard to the respective spreadbundles Ts in transit, as if a bow is rubbed against strings for playinga violin. In other words, there is no other difference between theapparatus example 3 and the apparatus example 2 excepting the provisionof the friction system 6 hereof.

The back-and-forth friction system 6 of the apparatus example 3comprises bow bars 61 and 61 that are disposed such that they make aline contact widthwise with regard to the respective spread bundles Tsin transit and a crank mechanism indicated with 62 and 63 to make thosebow bars move back-and-forth widthwise with regard to the respectivespread bundles Ts and a crank motor 64 to give a driving force to thecrank mechanism. A circular pipe made from stainless steel withroughening finish on the surface so as to enhance friction is adoptedfor any one of those bow bars.

The respective spread bundles Ts in transit after having passed thoughthe tensile force variable system 4 meet with those bow bars 61 and 61reciprocally moving back-and-forth while they pass through the frictionsystem 6 so as to be subjected to back-and-forth friction widthwisethereto, in which the respective monofilaments comprising the spreadbundles Ts respectively are rubbed one by one and even a portion of thespread bundle where adjacent monofilaments are bonded together is softlyseparated so that a high-quality spread multi-filament bundles sheet Twis formed with the respective spread bundles Ts uniformly distributedtherein.

Apparatus Example 4

The method of producing a spread multi-filament bundles sheet accordingto the third embodiment may be carried out also by use of an apparatusexample 4 as shown in FIGS. 9 and 10.

The apparatus example 4 is characterized in the provision of a floatingcontrol bridge 35 in the respective fluid flowing portions 31 a, 31 band 31 c to secure a minimum degree by which the respective bundlesTm•Tm . . . passing through each of those portions are bent, and theother structural arrangement thereof is the same as the apparatusexample 3.

With the third embodiment carried out by use of the apparatus example 4,the respective bundles Tm•Tm . . . are subjected to suction air streamwith each of those bundles passed under a floating control bridge 35provided at the respective fluid flowing portions 31 a, 31 b and 31 c.Thus, even if the tension force applied to the respective bundles Tmpassing through those portions is intensified by the action of thetensile force variable system 4 and the like, the respective bundles Tmare abutted onto the floating control bridges 35 so as to be preventedfrom being straightened or a degree by which the respective bundles Tmare bent from being smaller than secured by the floating control bridges35. Thus, the minimum contact area between the suction air stream andthe respective bundles Tm is secured so that the spreading operationperformed thereon at the fluid flowing spreader 3 is stabilized.

Apparatus Example 5

Then, the method of producing a spread multi-filament bundles sheetaccording to the third embodiment may be carried out also by use of anapparatus example 5 as shown in FIG. 11.

The difference between the apparatus example 4 and the apparatus example5 lies in that the latter is provided with a heater 7 such as a hot fanheater over the respective fluid flowing portions 31 a, 31 b and 31 c soas to blow hot air towards the respective bundles Tm passing throughthose portions, and the other structural arrangement thereof is the sameas the former.

The apparatus example 5 is particularly effective when the monofilamentscomprising the respective bundles Tm to be spread are bonded togetherwith a synthetic resin based sizing agent. Hot air blown from a hot fanheater adopted for the heater 7 in the apparatus example 5 softens thesizing agent to bond the monofilaments comprising the respective bundlesTm so as to relax the bonding between adjacent monofilaments, whichfurther promotes the spreading operation performed in those fluidflowing portions 31 a, 31 b and 31 c. The temperature of hot air dependson the type of a sizing agent in use, but in case of an epoxy basedsizing agent, such sizing material can be sufficiently softened by hotair ranging from 80 to 150 degrees Centigrade. To note, a far-infraredradiation heater, a high-frequency radiation heater may be adoptable forthe heater 7.

Apparatus Example 6

The method of producing a spread multi-filament bundles sheet accordingto the third embodiment may be carried out also by use of an apparatusexample 6 as shown in FIG. 12.

The difference between the apparatus example 5 and the apparatus example6 lies in that the latter is provided with a fluid flowing spreader 3 ofsuction cavity tube type whose opening is prolonged to a feedingdirection of the respective bundles Tm, which opening is equallysegmented into fluid flowing portions 31 a, 31 b and 31 c in this orderfrom an upstream side to a downstream side, and the other structuralarrangement thereof is the same as the former. The apparatus example 6requires only one flow rate valve 33 and a single suction air pump 34for the fluid flowing spreader 3 so that the manufacturing cost of anapparatus can be reduced and the operation thereof is simplified.

Fourth Embodiment

In the present embodiment, substantially the same apparatus as theapparatus example 5 as described above in which hot air is blown towardsthe respective fluid flowing portions 31 a, 31 b and 31 c by a heater 7such as a hot fan heater provided over those portions is arranged incomplexity so as to produce either spread multi-filament bundles orspread multi-filament bundles sheets, which bundles or sheets areoverlapped one over another to produce a complex spread multi-filamentbundles sheet. The production process of a commingled spreadmulti-filament bundles sheet is shown in FIGS. 13 through 15.

Apparatus Example 7

An apparatus example 7 is shown in FIG. 13, which apparatus is used forthe present embodiment. This apparatus example 7 has an upper and lowerarrangement, either of which arrangement is provided with a creel 1, amulti-filament bundle uni-directional feeder 2, a fluid flowing spreader3, a heater 7 and a guide roller 8, and further comprises a pair ofinflux rollers 9, a tensile force variable system 4, a widthwiseback-and-forth friction system 6 provided with bow bars 61 and 61 and atake-up system 5.

This apparatus example 7 is arranged such that a number ofmulti-filament bundles Tm•Tm . . . (five bundles herein) are unwoundfrom the respective upper and lower creels 1 and are moved to therespective fluid flowing spreaders 3 with a certain tensile forceapplied to each of those bundles by the respective uni-directionalmulti-filament bundles feeders 2 while with each of those bundles beingprevented from being drawn back by means of a nip roller and auni-directionally rotatable clutch. Then, the multi-filament bundlesTm•Tm . . . are subjected at the respective fluid flowing spreaders 3 tothe reciprocal change of the tensile force applied thereto betweentension and relaxation caused by the respective tensile force variablesystems 4 at a downstream side, under which change of the tensile forceapplied thereto each of those bundles is subjected to suction air streamso as to be spread. Thereafter, the respective bundles Tm are formedinto spread multi-filament bundles or a spread multi-filament bundlessheet, and such bundles or sheet moves towards the influx rollers 9through the respective guide rollers 8, at which influx roller 9 therespective upper and lower spread multi-filament bundles or therespective upper and lower spread multi-filament bundles sheets areoverlapped one over another so as to be stacked together and then to bemoved to the widthwise back-and-forth friction system 6 provided withthe bow bars 61 and 61 via the tensile force variable system 4. Then,the spread multi-filament bundles or the spread multi-filament bundlessheets as stacked are subjected to the fluctuation of the tensile forceapplied to the respective bundles or sheet as stacked between tensionand relaxation by the tensile force variable system 4, under whichfluctuation the spread multi-filament bundles or the spreadmulti-filament bundles sheets as stacked are subjected to back-and-forthfriction by the bow bars 61 and 61 of the widthwise back-and-forthfriction system 6 moving widthwise with regard to the bundles or thesheet as stacked. Hereupon, the respective monofilaments comprising theupper spread multi-filament bundles respectively or the upper spreadmulti-filament bundles sheet are uniformly commingled with thosecomprising the lower spread multi-filament bundles respectively or thelower spread multi-filament bundles sheet so as to be formed into acomplex spread multi-filament bundles sheet good at miscibility anduniform in thickness, which complex sheet is taken up by the take-upsystem 5 so as to be wound into a wind-up beam not shown in thedrawings.

FIG. 14 comprises illustrations to show the process in which the spreadmulti-filament bundles as stacked with the upper spread multi-filamentbundles overlapped with the lower spread multi-filament bundles areformed into a complex spread multi-filament bundles sheet. FIG. 15comprises illustrations to show the process in which the spreadmulti-filament bundles sheets as stacked with the upper spreadmulti-filament bundles sheet overlapped with the lower spreadmulti-filament bundles sheet are formed into a commingled spreadmulti-filament bundles sheet.

In the present embodiment as shown in FIGS. 13 through 15, it is shownthat the spread multi-filament bundles obtained in the upper and lowerstages respectively are overlapped one over another and intermingled soas to be formed into a complex spread multi-filament bundles sheet, butsuch multi-stages arrangement as comprising more than three stages maybe adoptable.

Further, the spread multi-filament bundles as stacked to be intermingledso as to be formed into a complex spread multi-filament bundles sheetare not limited to the same type of materials, but may be of differenttypes. For examples, not only the combination of the same types such asspread carbon fibers bundles overlapped over the same bundles, spreadpolypropylene resin fibers bundles stacked with the same bundles, butalso the combination of different types such as spread carbon fibersbundles overlapped over spread glass fibers bundles, spread carbonfibers bundles stacked with spread aramide resin fibers bundles or thecombination of reinforced fibers bundles and thermoplastic resin fibersbundles such as spread carbon fibers bundles overlapped with spreadpolypropylene resin fibers bundles, spread glass fibers bundles stackedwith spread nylon 6 resin fibers bundles are available.

Hereafter, the practical aspect of the invention is examined by showingthe following test examples on the basis of the first through fourthembodiments.

Test Example 1

In order to examine the workability of the first embodiment, thespreading operation is performed on a carbon fiber bundle by use of anapparatus arranged such that a hot fan heater used as a heater isfurther provided over the fluid flowing spreader 3 of the apparatusexample 1 as shown in FIG. 1.

In this test example, a carbon fibers bundle 12K marketed under thetrade name of ‘PYROFIL TR 50S’ produced by Mitsubishi Rayon Co., Ltd.,in which 12,000 carbon monofilaments respectively of 7 μm in diameterare bundled, is adopted for a test sample. Herein, the initial tensileforce of 40 g is applied to the carbon fibers bundle Tm by the tensionstabilizing roller 24 a, which bundle is fed to the fluid flowingspreader 3 of suction cavity type. The apparatus adopted herein isarranged as follows.

-   (1) The dimension of the opening over the fluid flowing portion 31 a    being 40 mm in width and 30 mm in length along a feeding course of    the bundle and the flow velocity of the suction air stream being set    at 20 m/second in an empty condition.-   (2) On an entrance side and an exit side of the fluid flowing    portion 31 a, a guide roller 32 having 10 mm in diameter and made    from stainless steel, the surface of which roller is satin finished,    being disposed.-   (3) The heater (hot fan heater) directed towards the fluid flowing    portion 31 a being capable of continuously blowing hot air of 120    degrees Centigrade thereto.-   (4) The crank motor 44 of the tensile force variable system 4 being    designed at 350 rpm and the pushdown stroke by the rod 42 to the    bundle being set at 20 mm.-   (5) The take-up speed of the bundle by the take-up system 5 being    set at 10 m/minute.

In this test example, the carbon fibers bundle 12 K whose initial widthis 5 mm and whose initial thickness is 0.15 mm before being subjected tothe spreading operation is formed into a spread fibers bundle Ts whosewidth is 20 mm and whose thickness is 0.04 mm. Commercially speaking, itis confirmed that this spread fibers bundle Ts is stable in spreadwidth, the alignment and distribution of which monofilaments are good.

Test Example 2

Five carbon fibers bundles are simultaneously spread by use of theapparatus example 2 as shown in FIG. 4 with a heater 7 (hot fan heater)provided over the fluid flowing spreader 3 thereof and a floatingcontrol bridge 35 internally provided at the depth of 10 cm of therespective fluid flowing portions 31 a, 31 b and 31 c so as to be formedinto five spread fibers bundles. Herein, a carbon fibers bundle 6Kmarketed under the trade name of TORAYCA M55J manufactured by Toray Co.,Ltd., in which 6000 carbon fibers having a higher elastic modulus of 540GPa respectively are bundled, is adopted for the carbon fibers bundle.The elastic modulus of a generally used carbon fiber amounts to about240 Gpa.

In this test example, five yarn suppliers 11 are disposed such that fivefibers bundles Tm•Tm . . . are lined widthwise with an interval of 10 mmbetween them and it is adjusted by the tension stabilizing roller 24 asuch that the tensile force applied to the respective bundles Tm becomes25 g. Those bundles are then fed to the fluid flowing spreader 3provided with the fluid flowing portions 31 a, 31 b and 31 c of suctioncavity tube type in this order. The apparatus used herein is arranged asfollows.

-   (1) The dimension of the opening of the respective fluid flowing    portions 31 a, 31 b and 31 c being 50 mm in width and 30 mm in    length along the feeding course of the respective bundles and the    flow velocity of the suction air stream being set at 20 m/second in    an empty condition.-   (2) On an entrance side and an exit side of the respective fluid    flowing portions, a guide roller 32 having 10 mm in diameter and    made from stainless steel whose surface is satin finished being    provided.-   (3) A heater (hot fan heater) directed towards the respective fluid    flowing portions being capable of continuously blowing hot air of    120 degrees Centigrade thereto.-   (4) The crank motor 44 of the tensile force variable system 4 being    designed at 350 rpm and the push-down stroke by the rod 42 to the    respective bundles being set at 20 mm.-   (5) The take-up speed of the respective bundles by the take-up    system 5 being set at 10 m/minute.

In this test example, the carbon fibers bundle 6K whose initial width is1 mm and whose initial thickness is 0.2 mm before being subjected to thespreading operation is formed into five spread carbon fibers bundles Tsrespectively. It is confirmed that there is almost no cut on themonofilaments in spite of the fact that a carbon fiber of higher elasticmodulus is in use and the monofilaments of the respective spread bundleare aligned and distributed orderly and uniformly.

Test Example 3

In this test example, 16 carbon fibers bundles are simultaneously spreadand consolidated into a spread multi-filament bundles sheet by use ofthe apparatus example 5 as shown in FIG. 11. A carbon fibers bundle 12Kmarketed under the trade name of ‘PYROFIL TR 50S’ manufactured byMitsubishi Rayon Co., Ltd., in which 12,000 monofilaments respectivelyhaving 7 μm in diameter are bundled, is adopted for the test sample.

Herein, 16 yarn supply bobbins are disposed such that 16 fibers bundlesTm are lined widthwise with an interval of 20 mm between them and it isadjusted by the tension stabilizing roller 24 a such that the tensileforce applied to the respective bundles becomes 40 g. Then, thosebundles are fed to the fluid flowing spreader 3 provided with the fluidflowing portions 31 a, 31 b and 31 c of suction cavity tube type. Theopening of the respective fluid flowing portions has 320 mm in width and30 mm in length along the feeding course of the bundles and the flowvelocity of the suction air stream is set at 25 m/second in an emptycondition. The respective fluid flowing portions are provided with afloating control bridge 35 having 10 mm in diameter at the depth of 10mm from a moving course of the respective bundles. A circular rod madefrom stainless steel whose ‘surface ’ is satin finished is adopted forthe floating control bridge. Then, hot air of 120 degrees Centigrade isblown to the respective bundles Tm in the process of being spread fromthe heater 7 (hot fan heater) disposed opposite to the respective fluidflowing portions. The crank motor 44 of the tensile force variablesystem 4 revolves at 350 rpm and the push-down stroke to the respectivebundles by the rod 42 is set at 20 mm. Further, the widthwiseback-and-forth friction system 6 is provided with two bow barsrespectively made from a stainless steel circular rod whose surface issatin finished, the crank motor 65 of which system 6 revolves at 200 rpmand the back-and-forth stroke of which bow bars respectively is set at 4mm so as to apply a back-and-forth friction widthwise with regard to aspread multi-filament bundles sheet. In this example, the take-up speedof the respective bundles by the take-up system 5 is set at 10 m/minute.

As a result of the above test, each of the carbon fibers bundles 12Kwhose initial width is 5 mm and whose initial thickness is 0.15 mmbefore being subjected to the spreading operation is processed into aspread fibers bundle having 20 mm in width. Those spread bundles Ts areconsolidated into a spread multi-filament bundles sheet Tw having 320 mmin width and 0.04 mm in thickness wherein the fringe side monofilamentsof any adjacent spread bundles Ts are tangentially aligned in an orderlymanner and the monofilaments as a whole are distributed-uniformly indensity.

Test Example 4

Herein, 16 carbon fibers bundles are simultaneously spread andconsolidated into a spread multi-filament bundles sheet by use of theapparatus example 6 as shown in FIG. 12. A carbon fibers bundle 12Kmarketed under the trade name of ‘PYRONFIL TR 50S’ manufactured byMitsubishi Rayon Co., Ltd., in which 12,000 monofilaments respectivelyhaving 7 min diameter are bundled, is adopted for the test sample.

Herein, 16 yarn supply bobbins are disposed such that 16 carbon fibersbundles Tm are lined widthwise with an interval of 20 mm between themand it is adjusted by the tension stabilizing roller 24 a such that thetensile force of 40 g is applied to the respective bundles Tm. Thosebundles are fed to the fluid flowing spreader 3 provided with the fluidflowing portions 31 a, 31 b and 31 c which are formed by segmenting alengthwise opening of the suction cavity tube running along the movingcourse of the bundles with a certain interval between them. The fluidflowing spreader 3 has 320 mm in width whose segmented fluid flowingportions respectively have 30 mm in length along the moving course ofthe respective bundles. A guide roller 32 is made from stainless steelcircular rod having 1.0 mm in diameter whose surface is satin finished.A suction air pump 34 operates by regulating the flow rate adjustmentvalve 33 such that the flow velocity of the suction air stream in thefluid flowing spreader 3 is set at 25 m/second in an empty condition.Further, the respective fluid flowing portions as segmented are providedwith a floating control bridge 35 having 10 mm in diameter at the depthof 10 mm from the moving course of the bundles. Then, hot air of 120degrees Centigrade is continuously blown to the respective bundles inthe process of being spread from the heater 7 (hot fan heater) providedover the fluid flowing spreader 3. The crankmotor 44 of the tensileforce variable system 4 revolves at 350 rpm and the pushdown stroke bythe rod 42 to the respective bundles is set at 20 mm. On the other hand,the crank motor 65 of the widthwise back-and-forth friction system 6revolves at 200 rpm and the back-and-forth stroke of the bow barsthereof 61 and 61 respectively is set at 4 mm, thereby, the surface of aspread multi-filament bundles sheet Tw in passage being subjected toreciprocally back-and-forth friction widthwise thereto. The spreadmulti-filament bundles sheet Tw is taken up by the take-up system 5 at10 m/minute.

As result of the above test, the respective carbon fibers bundles 12Kwhose initial width is 5 mm and whose initial thickness is 0.15 mmbefore being subjected to the spreading operation are processed into therespective spread fibers bundles Ts having 20 mm in width. Those spreadbundles Ts are consolidated into a spread multi-filament bundles sheetTw having 320 mm in width and 0.04 mm in thickness wherein the fringeside monofilaments of any adjacent spread bundles are tangentiallyaligned in an orderly manner and the monofilaments as a whole aredistributed uniformly in density.

Test Example 5

Herein, 16 carbon fibers bundles are simultaneously spread andconsolidated into a spread multi-filament bundles sheet by use of theapparatus example 7 as shown in FIG. 13. A carbon fibers bundle 12Kmarketed under the trade name of ‘PYROFIL TR 50S’ manufactured byMitsubishi Rayon Co., Ltd., in which 12,000 monofilaments respectivelyhaving 7 μm in diameter are bundled, is adopted for the test sample.

Eight yarn supply bobbins 11 are disposed on an upper creel 1 and asmany yarn supply bobbins are disposed on a lower creel 1 such that therespective fibers bundles Tm fed from the upper and lower creels 1 and 1respectively are lined widthwise with an interval of 40 mm between them.To note, the respective-fibers bundles Tm as proceeding in a movingcourse thereof are arranged such that any adjacent bundles are spacedapart by 20 mm. Then, the tensile force of 40 g is applied to therespective bundles Tm by the respective tension stabilizing rollers 24 aand are fed to the respective fluid flowing spreaders 3 provided withthe fluid flowing portions 31 a, 31 b and 31 c of suction cavity tubetype. The opening of the respective fluid flowing portions has 320 mm inwidth and 40 mm in length, in which the suction air stream is generatedat the flow velocity of 25 m/second in an empty condition. Therespective fluid flowing portions are provided with a floating controlbridge 35 having 10 mm in diameter at the depth of 10 mm from the upperedge thereof along the moving course of the bundles. Hot air of 120degrees Centigrade is continuously blown to the respective bundles fromthe heater 7 (hot fan heater) oppositely provided over the fluid flowingspreader 3. The crank motor 44 of the tensile force variable system 4revolves at 200 rpm and the pushdown stroke by the press roller 42 a tothe respective bundles is set at 20 mm. In turn, the back-and-forthstroke by the bow bars 61 and 61 respectively of the widthwiseback-and-forth friction system 6 is set at 4 mm, thereby, the spreadmulti-filament bundles sheet Tw in passage being subjected toreciprocally back-and-forth friction widthwise thereto. The spreadmulti-filament bundles sheet Tw is taken up by the take-up system 5 at10 m/minute.

As a result of the above test, the respective carbon fibers bundles 12Kwhose initial width is 5 mm and whose initial thickness is 0.15 mmbefore being subjected to the spreading operation are processed into therespective spread bundles Ts having 40 mm in width upon passing throughthe upper and lower fluid flowing spreaders 3. Those spread bundles Tsare fed from the upper and lower fluid flowing spreaders 3 respectivelyin the form of a spread multi-filaments sheet Tw with the fringe sidemonofilaments of any adjacent spread bundles Ts and Ts tangentiallyaligned and then overlapped one over another at the influx rollers 9 viathe respective guide rollers 8, which sheets as overlapped are subjectedto back-and-forth friction widthwise thereto by the widthwiseback-and-forth friction system 6 so as to be formed into a commingledspread multi-filament bundles sheet Tw with the monofilaments thereof asa whole distributed and intermingled with each other uniformly indensity, which commingled sheet has 320 mm in width and 0.04 mm inthickness.

The test examples on the basis of the first through fourth embodimentsare described above, and the other embodiments of the invention arefurther explained as follows.

Fifth Embodiment

The ‘method of producing a spread multi-filament bundle’ according tothe present embodiment is explained on the basis of an apparatus example8 as shown in FIGS. 16 and 17.

With reference to FIGS. 16 and 17, a carbon multi-filament bundle Tmhaving a diameter of 5 mm, in which 12,000 monofilaments respectivelyhaving 7 μm in diameter are bundled, marketed under the item number of‘TR 50S’ manufactured by Mitsubishi Rayon Co., Ltd., is drawn out from ayarn supply bobbin 11 by the multi-filament bundle feeder 2 and is thenfed to the fluid flowing spreader 3 with a velocity of 10 m/minute uponpassing through a streak of rollers 21 and 22 (23).

The carbon multi-filament bundle Tm as fed to the fluid flowing spreader3 moves from an upstream side to a downstream side by passing throughthe opened suction cavity of the respective fluid flowing portions 31 a,31 b, 31 c and 31 d in which suction air stream with a velocity of 20m/second is generated. Hereupon, the multi-filament bundle in contactwith the suction air stream is bent towards the flowing direction of thesuction air so as to increase the contact area between the bundle Tm andthe air stream. The enlargement of such contact area permits the airstream to flow through any adjacent monofilaments of the bundle Tm so asto slacken the bonding thereof, which starts spreading themulti-filament bundle. While the bundle Tm moves from the fluid flowingportion 31 a at an upstream side via the fluid flowing portion 31 b tothe portion 31 c at a downstream side, the bundle is gradually beingspread and is processed into a spread multi-filament bundle Ts havingabout 25 mm in width upon passing the portion 31 d located at thefarthest downstream side.

Apparatus Example 8

FIGS. 16 and 17 show an apparatus used for the ‘method of producing aspread multi-filament bundle’ according to the above fifth embodiment.

Namely, reference numeral 11 in the drawings indicates a yarn supplierof bobbin type, around which bobbin a fibers bundle Tm is wound.

Then, reference numeral 2 therein indicates a multi-filament bundlefeeder, which supplier comprises a pair of support rollers 21 and 22disposed with an interval between them to support a fibers bundles Tmunwound from the yarn supplier 11 in a fixed elevation level;uni-directionally driving rollers 23 and 23 to draw out the bundle Tmfrom the yarn supplier 11 with the bundle sandwiched between them; atension stabilizing dumper 24 provided with a rotatable tensionstabilizing roller 24 a at a lower end portion thereof and disposedbetween the support rollers 21 and 22, which tension stabilizing roller24 a abuts the bundle Tm unwound from the supplier 11 at a constantpressure so that the roller 24 a in abutment with the bundle Tmcontinues pressing against the bundle Tm so as to increase the degree bywhich the bundle is bent together with the increment of the tensionapplied thereto until the tensile force applied thereto becomes apredetermined level when the tensile force applied thereto is smallerthan such predetermined level and inferior to the pressure applied bythe roller while the roller 24 a in abutment with the bundle continuesretracting so as to decrease the degree by which the bundle is bentuntil the tensile force applied thereto becomes a predetermined levelwhen the tensile force applied thereto is larger than such predeterminedlevel and superior to the pressure applied by the roller. The bundle Tmthat is unwound from the multi-filament bundle feeder 2 and pass betweenthe uni-directionally driving rollers 23 and 23 is fed to a fluidflowing spreader as described below.

Then, reference numeral 3 therein indicates a fluid flowing spreader ofsuction cavity tube type, which spreader is provided with the respectivefluid flowing portions 31 a, 31 b, 31 c and 31 d. Namely, the respectivefluid flowing portions are disposed in the same elevation level alongthe moving course of the fibers bundle Tm, on an entrance side and anexit side of which respective portions, a guide roller 32 to keep thebundle in passage at a certain elevation level is provided. Therespective suction cavity tubes are provided with a suction air pump 34,the operation of which pump by regulating the suction air with a flowrate adjustment valve 33 as necessary causes a suction air stream with avelocity as required for the respective portions. The fibers bundle Tmpassing through those fluid flowing portions bends towards the flowingdirection of the suction air in contact therewith, which suction airflows through adjacent monofilaments thereof so as to be performedspreading operation thereon.

Then, reference numeral 51 therein indicates a take-up roller to take upa spread multi-filament bundle Ts after the passage through those fluidflowing portions at the velocity of 10 m/minute, which spread bundle Tsafter the passage through the take-up rollers 51 and 51 is wound uparound a winding beam B.

Sixth Embodiment

The ‘method of producing a spread fibers bundles sheet’ according to thepresent embodiment is explained on the basis of an apparatus example 9as shown in FIGS. 18 and 19.

The respective carbon multi-filament bundles Tm•Tm•Tm respectivelyhaving 5 mm in diameter, in which 12,000 monofilaments respectivelyhaving 7 μm in diameter, marketed under the item number of ‘TR 50S’manufactured by Mitsubishi Rayon Co, Ltd., are unwound from therespective bobbins 11•11•11 by the respective multi-filament bundlefeeders 2 and at the same velocity fed to the fluid flowing spreader 3with aligned in parallel in the same plane and spaced apart with anequal interval between them while passing through the uni-directionallydriving rollers 23 and 23.

The respective multi-filament bundles Tm•Tm•Tm fed to the fluid flowingspreader 3 move from an upstream side to a downstream side by passingthrough the opened cavity tube of the respective fluid flowing portions31 a, 31 b, 31 c and 31 d in succession in which the suction air streamwith a velocity of 20 m/second is generated. Hereupon, the respectivemulti-filament bundles Tm in contact with the suction air stream bendtowards the flowing direction of the suction air so as to increase thecontact area between the respective bundles and the suction air stream.The enlargement of such contact area allows the suction air stream toflow through any adjacent monofilaments of the respective bundles Tm soas to slacken the bonding thereof, which starts spreading the respectivebundles. While the respective bundles Tm•Tm•Tm move from the fluidflowing portion 31 a at an upstream side via the fluid flowing portion31 b to the portion 31 c at a downstream side, they are gradually beingspread and processed into a spread multi-filament bundles sheet Twhaving about 60 mm in width with the fringe side monofilaments of anyadjacent bundles tangentially aligned upon passing the portion 31 d atthe farthest downstream side.

Apparatus Example 9

FIGS. 18 and 19 show an apparatus example 9 that is used in the ‘methodof producing a spread fibers bundles sheet’ according to the sixthembodiment.

Namely, in the drawings, reference numeral 1 indicates a creel ontowhich three yarn suppliers 11•11•11 of bobbin type are suspended, aroundwhich suppliers respectively a fibers bundle Tm is wound. To note, onlythree suppliers are shown, the number of which suppliers may be modifiedinto as many suppliers as necessary through pegs arrangement.

Then, reference numeral 2 therein indicates a multi-filament bundlefeeder, which bundle feeder comprises uni-directionally driving rollers23 and 23 to draw out the respective fibers bundles Tm•Tm•Tm from therespective yarn suppliers 11 and to feed those fibers bundles inparallel with aligned in the same plane and at the same speed; supportrollers 21 and 22 intervening between the uni-directionally drivingrollers 23 and 23 and the respective suppliers 11 and disposed in amulti-stage arrangement (three stages being shown herein) to support therespective fibers bundles Tm•Tm•Tm as unwound in a fixed position; atension stabilizing dumper 24 of each stages disposed between thesupport rollers 21 and 22 and provided with a tension stabilizing roller24 a at a lower end portion thereof, which roller 24 a abuts therespective fibers bundle Tm of each stages unwound from the respectiveyarn suppliers 11 under a constant pressure so that the roller 24 a inabutment with the respective fibers bundles Tm continues pressingagainst the latter so as to increase the tension applied thereto untilsuch tension becomes a predetermined level when the tension of therespective fibers bundles is smaller than such predetermined level whilethe roller 24 a in abutment therewith is bounced back by the respectivefibers bundles Tm to retract when the tension thereof is larger thansuch predetermined level so as to keep the tension applied to therespective fibers bundles constant. The respective fibers bundlesTm•Tm•Tm carried forwards by the respective multi-filament bundlefeeders 2 are fed with a certain tension applied thereto to a fluidflowing spreader 3 as described below with each of them aligned inparallel in the same plane and spaced apart with an equal interval uponpassing through the uni-directionally driving rollers 23 and 23.

Then, reference numeral 3 therein indicates a fluid flowing spreader ofsuction cavity tube type, which spreader comprises four fluid flowingportions 31 a, 31 b, 31 c and 31 d respectively having an opening on thetop. Namely, the respective fluid flowing portions are disposed in thesame elevation level along the moving course of the respective fibersbundles that are fed in parallel with aligned in the same plane and withthe same speed by the uni-directionally driving rollers 23 and 23, on anentrance side and an exit side of which respective portions a guideroller 32 is provided to keep the respective fibers bundles in passagein a certain elevation level. A suction air pump 34 is engaged to therespective suction cavity tubes of the apparatus example 9, theoperation of which pump with the suction air regulated with a flow rateadjustment valve 33 as necessary causes suction air stream with avelocity as required for the respective fluid flowing portions 31 a, 31b, 31 c and 31 d. The respective fibers bundles Tm•Tm•Tm passing throughthose fluid flowing portions bend towards the flowing direction of thesuction air stream in contact therewith, which suction air stream flowsthrough any adjacent monofilaments of the respective bundles so as to beperformed spreading operation thereon.

Reference numerals 51 and 51 indicate take-up rollers to take up aspread multi-filament bundles sheet Tw passed through the respectivefluid flowing portions 31 a, 31 b, 31 c and 31 d at the velocity of 10m/minute, which sheet passed between those take-up rollers is wound upby a winding beam B.

Apparatus Example 10

FIGS. 20 through 23 show another apparatus example 10 that is used inthe ‘method of producing a spread multi-filament bundles sheet’according to the sixth embodiment. This apparatus 10 is characterized inthat a floating control bridge 35 is provided in the respective fluidflowing portions 31 a, 31 b, 31 c and 31 d of the apparatus example 9crosswise to the moving course of the respective fibers bundles Tm, andthe other structural arrangement thereof is the same as that of theapparatus example 9. In order to perform spreading operation on therespective fibers bundles by means of this apparatus 10, the respectivefibers bundles are subjected to suction air stream with each of thempassed under the respective bridges 35 so that there is no case wherethe respective bundles moving through those fluid flowing portions arestraightened or the degree by which they are bent becomes smaller than apredetermined minimum levele, which results in improving spreadingefficiency with wider contact area with the suction air stream. Inaddition, the apparatus 10 is modified such that the elevation level ofthe respective bridges 35 may be arranged vertically movable by means ofa well-known cross bar system not shown in the drawings.

Commenting further, when a floating control bridge 35 is provided insidethe respective fluid flowing portions 31 a, 31 b, 31 c and 31 d like theapparatus 10, as shown in FIG. 23, the fibers bundle Tm in the processof being spread proceeds along the moving course thereof with only themonofilaments located in the vicinity of each fringe side thereof incontact with the bridge 35 while those located in the central portionthereof suctioned by the suction air stream so as to separate from thebridge. Thus, in case of the fibers bundle Tm being spread by the actionof suction air, there is no inconsistency in spread monofilaments lengthbetween the central portion and each fringe side portions thereof so asto gain a widely spread multi-filament bundle, the distribution of whichmonofilaments is better.

Apparatus Example 11

FIG. 24 shows another apparatus example 11 that is used in the ‘methodof producing a spread multi-filament bundles sheet’ according to thesixth embodiment. This apparatus example 11 is characterized in that atensile force variable system 4 of up-and-down press roller typeintervenes between the uni-directionally driving rollers 23 and 23 and aguide roller 32 on the entrance side of the foremost fluid flowingportion 31 a, and the other structural arrangement thereof is the sameas the apparatus example 10. The tensile force variable system 4 hereofis composed of a rod member extending crosswise to the moving course ofthe fibers bundle Tm, which member is intended for moving up and downand crosswise with regard to the respective fibers bundles Tm•Tm•Tm fedin parallel from the yarn supply creel in the same plane and at the samespeed so as to simultaneously change the tensile force applied to therespective fibers bundles Tm in carriage alternatively and repeatedlybetween tension and relaxation. When the respective fibers bundles Tmmoving between the uni-directionally driving rollers 23 and 23 and aguide roller 32 on the entrance side of the foremost fluid flowingportion 31 a are subjected to such an intermittent press by the tensileforce variable system 4, the bonding between the adjacent monofilamentscorresponding to a portion of the respective fibers bundles rubbed andpressed by the tensile force variable system 4 is slackened and thetensile force applied to the respective fibers bundles Tm moving towardsthe fluid flowing portions 31 a, 31 b, 31 c and 31 d repeatedly changesbetween tension and relaxation at a certain timing. Such change of thetensile force applied to the respective fibers bundles, the bonding ofwhich adjacent monofilaments is slackened, brings favorable spreadingeffect thereon when they are subjected to suction air stream at therespective fluid flowing portions 31 a, 31 b, 31 c and 31 d. Namely,when the tensile force applied to the respective fibers bundles Tmchanges to relaxation, each of them moving through the respective fluidflowing portions bends to a large extent so as to increase the contactarea with the suction air stream, resulting in the respective bundlesbeing spread further while such change of the tensile force applied tothe respective bundles is leveled out during each of them moving fromthe foremost fluid flowing portion 31 a to the farthest fluid flowingportions 31 d, in which condition a spread multi-filament bundles sheetTw is wound up by a wind-up beam B.

Apparatus Example 12

FIGS. 25 through 27 show another apparatus example 12 that is used inthe ‘method of producing a spread multi-filament bundles sheet’ inaccordance with the above sixth embodiment. The difference between theapparatus example 9 and this apparatus lies in that the latter isprovided with a guide roller 32 disposed on an entrance side and an exitside of the respective fluid flowing portions for the purpose ofsupporting the respective bundles Tm in a certain elevation level andarranged such that it reciprocally moves back and forth widthwise withregard to the moving course of the respective bundles, and the otherstructural arrangement thereof is the same as the former. Namely, therespective guide rollers 32 hereof are engaged to a well-known linkagemechanism 32 c connected to a crank arm 32 b driven by a crank motor 32a, and upon the rotation of the crank motor 32 a, the crank arm 32 bconverts such rotation into a back-and-forth motion, which motion istransmitted to the linkage 32 c so as to make the respective guiderollers 32 simultaneously move back and forth. The respectivemonofilaments of those bundles moving in linear contact with amulti-filament bundle friction system M hereof are rubbed through thereciprocal back-and-forth movement of the respective guide rollerscomprising the system M so that even a portion of the respective bundleswhere the adjacent monofilaments thereof are firmly bonded together istenderly separated from each other so as to further enhance thespreading operation by the action of suction air thereon at therespective fluid flowing portions 31 a, 31 b, 31 c and 31 d.

Apparatus Example 13

FIG. 28 shows another apparatus example 13 that is used in the ‘methodof producing a spread multi-filament bundles sheet’ according to theabove sixth embodiment. The difference between this apparatus and theapparatus example 9 lies in that the former is provided with a heater 7(hot fan heater) disposed opposite to the respective fluid flowingportions 31 a, 31 b, 31 c and 31 d, and the other structural arrangementthereof is the same as the latter. This apparatus is effectiveparticularly when the respective monofilaments of the multi-filamentbundles Tm respectively are bonded together with a synthetic resin basedsizing agent. Upon hot air of 120 degrees Centigrade being blown towardsthe respective fluid portions, the sizing agent with which themonofilaments of the respective bundles are bonded together is softenedso as to further enhance spreading operation by the action of suctionair at the respective fluid portions.

Apparatus Example 14

FIG. 29 shows another apparatus 14 that is used in the ‘method ofproducing a spread multi-filament bundles sheet’ in accordance with theabove sixth embodiment. The difference between this apparatus and theapparatus example 9 lies in that the former is provided with thearrangement such that a prolonged opening of the suction cavity tubewith regard to the moving course of the respective bundles is segmentedinto the respective fluid flowing portions 31 a, 31 b, 31 c and 31 d,and the other structural arrangement thereof is the same as the latter.In comparison with the apparatus example 9, only one suction pump 34 andthe sole flow rate adjustment valve 33 are required for the apparatushereof, which results in reducing the manufacturing cost of theapparatus and facilitating the operation thereof.

Apparatus Example 15

FIG. 30 shows an apparatus example 15 that is used in the ‘method ofproducing a spread multi-filament bundles sheet’ according to the abovesixth embodiment. The difference between the apparatus example 14 andthis apparatus lies in that a floating control bridge 35 is provided inthe respective fluid flowing portions, and the other structuralarrangement thereof is the same as the apparatus example 14. Thisfloating control bridge 35 works in the same way as that of theapparatus example 9.

Apparatus Example 16

FIG. 31 shows another apparatus example 16 that is used in the ‘methodof producing a spread multi-filament bundles sheet’ according to theabove sixth embodiment. The difference between this apparatus and theapparatus example 9 lies in that the former is provided with a sealingplate 31 s covering an opening of the respective fluid flowing portionsso as to provide each of them with an opened area corresponding to thewidth of the respective bundles Tm in carriage, and the other structuralarrangement thereof is the same as the latter. The opening of therespective fluid flowing portions being covered with such sealing plate31 s, energy loss due to wasteful use of suction air is prevented so asto save operation cost.

Seventh Embodiment

The ‘method of producing a spread multi-filament bundles sheet’according to the present embodiment is described as follows on the basisof an apparatus example 17 as shown in FIG. 32.

The respective carbon multi-filament bundles Tm having 5 mm in diameterand drawn out from the respective bobbins 11 of the creel 1 by means ofthe multi-filament bundle feeder 2, in which 12,000 monofilamentsrespectively having 7 μm in diameter are bundled and marketed byMitsubishi Rayon Co., Ltd. under the item number of ‘TR 50S’, are at thesame speed fed to the fluid flowing spreader 3 with aligned in parallelin the same plane and with an equal interval between them upon passingthrough the uni-directionally driving rollers 23 and 23.

During the respective bundles Tm moving from the uni-directionallydriving rollers 23 and 23 towards the wind-up beam B, they pass throughthe respective fluid flowing portions 31 a, 31 b, 31 c and 31 d ofwater-sealed tube type through which hot water of 80 degrees Centigradecirculates at the flow rate of 5 m/second. Hereupon, the respectivebundles Tm pass through in suspension the respective fluid flowingportions via the respective watertight yarn passage holes h. Therespective bundles Tm in contact with the circulating hot water at thattime bend towards the flowing direction thereof so as to graduallyincrease the contact area between the respective bundles and thecirculating hot water. The enlargement of the contact area between themallows the circulating hot water to further flow through the adjacentmonofilaments of the respective bundles so as to slacken the bonding ofthe monofilaments thereof or further enhance spreading operation. Thus,during the respective bundles Tm moving from the foremost fluid flowingportion 31 a via 31 b to 31 c, each of those bundles are gradually beingspread, and when they are done with passing over the farthest fluidflowing portion 31 d, a widely spread multi-filament bundles sheet Twhaving about 75 mm in width with the side fringe adjacent monofilamentsof the respective bundles Tm-tangentially aligned side by side isproduced.

Apparatus Example 17

FIG. 32 shows an apparatus example 17 that is used in the ‘method ofproducing a spread multi-filament bundles sheet’ according to theseventh embodiment. Reference numeral 1 therein indicates a creel, towhich three bobbins 11 are suspended, and a multi-filament bundle Tm iswound around each of those bobbins. Reference numeral 2 thereinindicates a multi-filament bundle feeder, which feeder comprisesuni-directionally driving rollers 23 and 23 to unwind the respectivebundles Tm from the respective bobbins 11 and to feed them with alignedin parallel in the same plane; a streak of anterior and posteriorsupport rollers 21 and 22 intervening between the uni-directionallydriving rollers 23 and 23 and the respective bobbins 11 to support therespective bundles Tm in a fixed position; and a tension stabilizingdumper 24 disposed between the pair of support rollers 21 and 22 andprovided with a tension stabilizing roller 24 a at a lower end portionthereof. The arrangement of the creel 1 and the multi-filaments feeder 2hereof respectively is the same as that of the apparatus example 9.

Then, reference numeral 3 therein indicates a fluid flowing spreader ofwater circulating system. This system 3 comprises four fluid flowingportions 31 a, 31 b, 31 c and 31 d of diametrically enlargedwater-sealed tube type respectively provided with a yarn passage hole hon both opposite sides thereof. Namely, those fluid flowing portionsrespectively are provided with a yarn passage hole h on both oppositesides thereof in the same elevation level along the moving course of therespective bundles, on an entrance side and an exit side of which fluidflowing portions respectively a yarn passage hole h is provided, arubber guide roller 32 is disposed to keep the respective bundles Tm inpassage in a certain elevation level along with preventing waterleakage. A liquid circulation pump 34 is connected to the respectivefluid flowing portions hereof, and upon the operation of the respectivecirculation pumps with the flow rate of a circulating liquid regulatedwith a flow rate adjustment valve 33, the circulation occurs with a flowvelocity as required for the respective fluid flowing portions throughthe respective circulation pipe 3 c. The respective bundles Tm passingthrough the respective yarn passage holes h of the respective fluidflowing portions and meeting with the circulating hot water bend towardsthe circulation direction thereof, which causes the circulating hotwater to flow through any adjacent monofilaments of the respectivebundles so as to be performed spreading operation thereon.

On an exit side of the farthest fluid flowing portion 31 d, a pair oftake-up rollers 51 and 51 are disposed, between which rollers a widelyspread multi-filament bundles sheet Tw coming out of the yarn passagehole h of the fluid flowing portion 31 d is taken up at the velocity of10 m/minute so as to be wound up around a wind-up beam B. To note,reference numeral 8 in FIG. 32 indicates a well-known drying roller toremove water from the spread multi-filament bundles sheet Tw coming outof the yarn passage hole h of the farthest fluid flowing portion 31 d ina wetted condition.

Apparatus Example 18

FIG. 33 shows an apparatus example 18 that is used in the ‘method ofproducing a spread multi-filament bundles sheet’ according to the aboveseventh embodiment. The difference between this apparatus and theapparatus example 17 lies in that the former is provided with a fluidflowing spreader 3 of diametrically enlarged water-sealed tube type,which spreader is segmented into the respective fluid flowing portions31 a, 31 b, 31 c and 31 d with an interval between them, and the otherstructural arrangement thereof is the same as the apparatus example 17.Only one circulation pump 34 and the sole flow rate adjustment valve 33are required for the apparatus hereof in comparison with the apparatusexample 17, so that the manufacturing cost thereof is reduced and theoperation thereof is facilitated.

The preferred embodiments of the invention are substantially describedabove, to which embodiments the invention is not limited, but it can bemodified into various manners within the scope of the accompanyingpatent claims. For instances, the following modified examples alsobelong to the technical scope of the invention.

-   (1) The creel 1 of the first through seventh embodiments and the    apparatus examples 1 through 18 respectively being arranged such    that the respective bundles Tm unwound from three to five bobbins    are processed, but the number of bobbins being not limited to three,    which number may be increased such that an arbitrary number of the    bundles unwound from as many bobbins is processed.-   (2) A floating control bridge 35 of circular rod type being adopted    for the first through seventh embodiments and the first through    eighteenth apparatus examples respectively, the central portion of    which rod may be formed into an entasis shape.-   (3) A heater 7 of hot fan heating type being adopted for some of the    above embodiments, which heater is not limited to a hot fan heater,    an ultrasonic oscillator or a far-infrared radiation device may be    adoptable instead.-   (4) In the above seventh embodiment, hot water of 80 degrees    Centigrade being used for providing a fluid friction to the    respective bundles Tm so as to spread them, which fluid friction may    be provided by cold water or warmed water, in addition to which, air    bubbles may be hit onto the monofilaments of the respective bundles    Tm by use of such liquid-gas two-phase flow as air bubbles    containing water so as to be broken in collision into particulate    bubbles, which particulate bubbles flow through any adjacent    monofilaments of the respective bundles that are slackened by such    collision.-   (5) Further, in the above third embodiment, a resin impregnation    process being provided in addition along the downstream side of the    apparatus example 5 as shown in FIG. 9, wherein a resin sheet St is    laid over to the respective upper and lower side surfaces of a    spread multi-filament bundles sheet Tw in the process of being    produced, over which respective resin sheets a release sheet Rs is    further laid, and the resin sheet St is fused onto the upper and    lower surfaces respectively of the spread sheet Tw by means of a    bonding device H, and then a pre-impregnation sheet P as obtained is    peeled off and wound up around a wind-up roller R.

INDUSTRIAL APPLICABILITY

In a method of producing a spread multi-filament bundle and an apparatusused in the same according to the invention, such mechanism is adoptedas passing in suspension a multi-filament bundle or a number ofmulti-filament bundles respectively unwound and fed from a supplier or acreel through a plurality of fluid flowing portions disposed insuccession along the moving course of the respective bundles to besubjected to fluidal resistance so as to bend towards a direction towhich a fluid flows and flowing the fluid through the adjacentmonofilaments of the respective bundles whose bonding is slackened dueto such fluidal resistance, which mechanism allows a spreadmulti-filament bundle to be produced with high efficiency while ahomogeneous and high-quality spread multi-filament bundles sheet to bemass-produced with the fringe side monofilaments of any adjacent bundlestangentially aligned in parallel and the monofilaments thereofdistributed uniformly in density, so that the industrial applicabilityof the invention is very high.

The structural arrangement of the apparatus according to the inventionis streamlined such that it essentially consists of a creel, amulti-filament bundle feeder, a fluid flowing spreader comprising aplurality of fluid flowing portions disposed in succession along themoving course of the respective bundles, by use of which apparatus suchmulti-filament bundles of higher strength as carbon fibers, ceramicfibers, polyoxymethylene fibers, aromatic polyamide fibers are spreadwith high efficiency and in a space-saving manner so as to produce aspread multi-filament bundle or s spread multi-filament bundles sheetwith lower production cost and higher productivity, so that theindustrial applicability of the invention is very high.

1. A method of producing a spread multi-filament bundle comprising thesteps of: subjecting a multi-filament bundle in carriage to fluctuationof a tensile force applied to said bundle alternatively between tensionand relaxation by locally and reciprocally pressing said bundle fed froma yarn supplier crosswise with regard to a moving course of said bundle;passing in suspension said multi-filament bundle moving under saidfluctuation through a plurality of fluid flowing portions in successioncomprising a fluid flowing spreader, said portions being disposed inseries along a moving course of said multi-filament bundle; subjectingsaid multi-filament bundle to fluidal resistance while said bundle movesthrough said respective fluid flowing portions so as to bend said bundletowards a direction to which a fluid in use flows; and flowing saidfluid through an interstice between any adjacent monofilaments of saidbundle whose bonding is slackened due to said fluidal resistance so asto widen said interstice, thereby, promoting spreading operation on saidbundle, wherein said multi-filament bundle to be subjected to saidspreading operation is continuously passed through said fluid flowingportion located in an upstream side of the spreader to said fluidflowing portion located in a downstream side of the spreader insuccession to gradually enlarge contact area between said bundle andsaid fluid so as to widely spread said multi-filament bundle in aprogressive manner.
 2. A method of producing a spread multi-filamentbundle according to claim 1 further comprising the steps of: providing alinearly back-and-forth friction widthwise with regard to said bundle.3. A method of producing a spread multi-filament bundle according toclaim 1 wherein said multi-filament bundle unwound from said yarnsupplier is fed while restrained from being drawn back.
 4. A method ofproducing a spread multi-filament bundle according to claim 3 wherein afloating control bridge to secure a degree by which said bundle bends ata predetermined level is provided in said plurality of fluid flowingportions respectively such that said bundle is put into contact with afluid under said floating control bridge so as not to make said degreeby which said bundle passing through said respective fluid flowingportions bends smaller than said predetermined level.
 5. A method ofproducing a spread multi-filament bundle according to claim 4 whereinsaid bundle passes in suspension through said respective fluid flowingportions respectively disposed in series along said moving course ofsaid bundle in such a manner that a sizing agent contained in saidbundle in passage is softened by heating so as to make bonding betweenmonofilaments comprising said bundle slackened.
 6. A method of producinga spread multi-filament bundle according to claim 1, wherein the methodis applied to respective multi-filament bundles unwound from respectiveyam suppliers of a creel aligned in parallel and in the same plane.
 7. Amethod of producing a spread multi-filament bundle according to claim 6,further comprising the step of: providing a linearly back-and-forthfriction widthwise with regard to a group of spread multi-filamentbundles moving in the same plane so as to produce a spreadmulti-filament bundles sheet with fringe side monofilaments of anyadjacent spread bundles tangentially aligned and monofilaments as awhole of said respective spread bundles uniformly distributed indensity.
 8. A method of producing a spread multi-filament bundleaccording to claim 1, wherein said tensile force is applied at a pointon the bundle upstream of the fluid flowing portions prior to saidbundle passing through the fluid flowing portions.
 9. A method ofproducing a spread multi-filament bundle according to claim 1, whereinsaid tensile force is applied to the spread multi-filament bundledownstream of the fluid flowing portions.
 10. A method of producing aspread multi-filament bundle according to claim 1, wherein said tensileforce is applied to the spread multi-filament bundle when passingthrough the fluid flowing portions.
 11. An apparatus for producing aspread multi-filament bundle comprising: one of a supplier and a creelprovided with a number of suppliers; a multi-filament bundle feeder tounwind one of a multi-filament bundle and a group of said multi-filamentbundles from one of said supplier and said suppliers of said creel undera certain tension and to feed one of said multi-filament bundle and saidgroup of multi-filament bundles with a restraint being drawn back whilekeeping one of said multi-filament bundle and said group ofmulti-filament bundles in a plane; a fluid flowing spreader providedwith a plurality of fluid flowing portions disposed in series along amoving course of one of said bundle and said group of bundlesrespectively to put a fluid into contact with and pass said fluidthrough one of said bundle and said group of bundles with one of saidbundle and said group of bundles in carriage supported in suspension,said fluid flowing crosswise with regard to said moving course; and atensile force variable system to change a tensile force applied to oneof said bundle and said group of bundles in carriage alternativelybetween tension and relaxation.
 12. An apparatus for producing a spreadmulti-filament bundle according to claim 11 wherein said tensile forcevariable system comprises an elevating rod provided with a press rollerat its lower end portion; a contractile and extensile crank arm engagedto said elevating rod; and a crank motor whose power shaft is providedwith a rotor in engagement with said crank arm.
 13. An apparatus forproducing a spread multi-filament bundle according to claim 11 wherein atension stabilizing mechanism is provided at an upstream side from saidfluid flowing spreader, said mechanism being provided with a tensionstabilizing roller to abut a multi-filament bundle unwound and fed fromone of a supplier and a creel under pressure and being arranged suchthat said tension stabilizing roller in abutment with said bundlecontinues pressing said bundle so as to increase a tensile force appliedto said bundle along with increasing a degree by which said bundle bendsuntil a predetermined tensile force is applied to said bundle when saidtensile force applied to said bundle decreases below said predeterminedtensile force and is inferior to a pressure applied by said roller whilesaid tension stabilizing roller in abutment with said bundles is bouncedback to retract along with decreasing said degree until saidpredetermined tensile force is applied to said bundle when said tensileforce applied to said bundle increases above said predetermined tensileforce and is superior to said pressure applied by said roller so as tokeep said tensile force applied to said bundle in carriage constant. 14.An apparatus for producing a spread multi-filament bundle according toclaim 11 wherein a floating control bridge running crosswise with regardto said moving course of one of said bundle and said group of bundles isprovided inside said respective fluid flowing portions.
 15. An apparatusfor producing a spread multi-filament bundle according to claim 14wherein said floating control bridge is formed into a cylindrical shapewhose middle portion diametrically bulges like an entasis.
 16. Anapparatus for producing a spread multi-filament bundle according toclaim 11 wherein a heater is disposed above and opposite to saidrespective fluid flowing portions so as to apply heating treatment onone of said bundle and said group of bundles in passage.
 17. Anapparatus for producing a spread multi-filament bundle according toclaim 11 wherein a widthwise back-and-forth friction system is disposedto provide back-and-forth friction widthwise with regard to one of saidbundle and said group of bundles in a process of being spread inabutment with monofilaments comprising said one of said bundle and saidgroup of bundles respectively.
 18. An apparatus for producing a spreadmulti-filament bundle according to claim 11 wherein a prolonged openingprovided along said moving course of one of said bundle and said groupof bundles is segmented into said respective fluid flowing portions withan interval.
 19. An apparatus for producing a spread multi-filamentbundle according to claim 11 wherein said plurality of fluid flowingportions respectively are of a diametrically enlarged watertight tube,on an entrance side and an exit side of which respective portions a yarnpassage hole is provided, said watertight tube being provided with aliquid circulation passage through a circulation pipe connected to acirculation pump, an operation of which pump causes circulating water tocirculate through at a flow velocity said respective fluid flowingportions via said circulation pipe to subject one of said bundle andsaid group of bundles to water resistance so as to bend said one of saidbundle and said group of bundles passing through said yam passage holesof said respective fluid flowing portions towards a direction to whichsaid circulating water flows, through an interstice between adjacentmonofilaments of one of said bundle and said group of bundlesrespectively said circulating water flows so as to widen saidinterstice.